REMOVAL & INSTALLATION
See Figures 1 and 2
- Place the steering wheel and front tires in the centered (straight ahead) position.
Anytime the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.
- Raise the van and support it safely with jackstands placed under the frame lifting pads. A hydraulic floor jack should be placed under the control arm to raise and lower the arm during coil spring removal. Make sure the van is supported securely on the jackstands and only work on one side at a time. Never service both front suspension assemblies at the same time.
- Remove the front wheel and tire assemblies from the front of the vehicle.
- Remove the upper ball joint-to-spindle bolt and nut. Disengage the upper ball joint from the spindle. When disconnecting the upper ball joint-to-spindle connection, use a floor jack to support the lower control arm. If the lower control arm is not supported, the spring may jump out of its seat, causing possible physical injury or component damage.
- Remove the bolt retainer plate screw. Remove the plate.
- Matchmark the position of the control arm mounting brackets on the flat plate.
- Remove the bolt and washer retaining the front mounting bracket to the flat plate.
- From beneath the rail, remove the three nuts from the bolts retaining the two upper control arm mounting brackets to the body rail.
- Remove the three long bolts retaining the mounting brackets to the body rail by rotating the upper control arm out of position in order to remove the bolts. Remove the upper control arm, upper ball joint and mounting bracket assembly, and the flat plate from the van.
- Inspect the upper and/or lower ball joint boot seal, and replace if necessary.
- If required to service the upper control arm and upper ball joint assembly, or the mounting brackets and adjusting arm assembly, remove the nuts retaining the upper control arm to the adjusting arm. Note the exact position and number of shims on each control arm stud. These shims control caster and camber. Remove the upper control arm from the adjusting arm.
The adjusting arm and mounting brackets are serviced as an assembly. Ford recommends that the upper control arm and upper ball joint also be serviced as an assembly; however; aftermarket ball joint kits are available.
- If necessary, remove the damper assembly from the upper control arm by removing the three retaining bolts.
- If removed, install the upper control arm in the adjusting arm. Install the shims on the control arm studs with the same number of shims in the exact position as marked during removal. Install and tighten the nuts retaining the shims to the control arm.
- Place the flat plate for the mounting brackets in position on the body rail, then install and tighten the bolts to 10-14 ft. lbs. (14-18 Nm).
- Place the mounting brackets and upper control arm assembly in position on the flat plate.
- Install the three long bolts and washers retaining the mounting brackets to the body rail. Rotate or rock the upper control arm and mounting bracket assembly until the bolt heads rest against the mounting bracket and the studs extend through the body rail.
Move the mounting brackets into the position marked on the flat plate during removal. Install and tighten the nuts and washers retaining the mounting bracket bolts to the body rail to the following specifications:
- 1986-90 models-135-142 ft. lbs. (175-185 Nm) for the front bolt, and 145-;152 ft. lbs. (188-198 Nm) for the center and rear bolts.
- 1991-96 models-all three bolts to 145-152 ft. lbs. (188-198 Nm).
Make sure the mounting brackets do not move from the marked position on the flat plate to minimize corrections.
- Install and tighten the smaller bolt retaining the front mounting bracket to the flat plate to 35-47 ft. lbs. (47-64 Nm).
- Place the bolt retainer plate and cowl drain bracket in position on the mounting bracket and flat plate assembly, then install and tighten the bolt to 10-14 ft. lbs. (14-18 Nm).
- Install the upper ball joint stud to the upper spindle/knuckle arm. Install and tighten the pinch bolt and nut to 27-37 ft. lbs. (37-50 Nm).
- Install the tire/wheel assemblies.
- Have the front end aligned. Caster and camber are adjusted by adding or removing shims.
CONTROL ARM BUSHING REPLACEMENT
The upper control arm bushings are integral to the upper control arm itself. These bushings are not replaceable, so the entire control arm assembly must be replaced as a set.